Choose cardboard divider height according to the contacts that must be prevented and the mechanical role expected from the divider. It should not automatically equal the full product height. A partition may protect a bottle body while leaving its closure accessible; products with projecting upper parts may require a more complete separation arrangement.
Draw the areas that could meet
Place the products in their shipping orientation and examine nearby features: bodies, shoulders, necks, pumps and handles. Mark them on a side view. The useful question is where contact could occur if products move within the pack. A wall tall enough to separate their bodies may still allow accessories to meet above its top edge.
Include differences between product references. In a mixed pack, one item may extend well above the others, so the divider may not perform the same function in every cell. An additional component, a different orientation or a separate packing arrangement may be preferable to raising every partition. Record the alternatives so that the final choice can be traced to a specific contact problem.
Distinguish separation from load support
A divider separates products, but some designs may also participate in supporting loads. State these functions explicitly. If the top of the pack bears on the products, the load follows a different path from a system that uses divider walls as supports. Changing their height can therefore alter the way forces travel through the pack, even when the revised arrangement looks easier to assemble.
Estic-Maillot’s cardboard partition information distinguishes applications where a divider has a load-bearing role. This does not mean that any partition can support a specified load. Material, assembly, geometry and complete-pack testing remain relevant. Identify which parts are intended to carry forces and which must remain unloaded, particularly pumps, caps or fragile attachments.
Preserve the intended box closure
Measure the space below the flaps or lid after the base and accessories are installed. An overly tall divider may interfere with closure, press on a pump or distort a top pad. An operator may manage to close the box by applying extra force, unintentionally transferring that force to the product. Such a technique should not become the normal packing method.
Use the components intended for production: box, tape, base pad, top pad and complete product. Check that closure does not require unusual manual compression. Reopen the box and look for contact marks. A mark on the lid can help identify an interaction, but it does not by itself establish whether the assembly performs satisfactorily throughout distribution.
Keep loading and removal practical
A high partition can restrict finger access or interfere with a mechanical gripper. A lower wall can improve access while leaving a sensitive area exposed. Trial the height with the actual operation: inserting individual products, loading a group, removing an item for inspection or carrying out a packing correction. The appropriate geometry should accommodate the intended operation without relying on an improvised manoeuvre.
In a hypothetical example, a bottle is 180 mm tall and its pump projects beyond the body. Selecting a 180 mm divider simply from that overall height would be premature. First identify acceptable contact levels, pump overhang and space beneath the lid. The study might lead to a lower divider with an additional upper component, or to another arrangement. Final dimensions come from validation rather than a standard percentage of product height.
Examine movement during the expected journey
Products may move vertically or tilt within the freedom allowed by the pack. Consider what happens when the package changes orientation under the agreed test conditions. Protection that appears satisfactory with the product upright may become inadequate if it moves away from the base. Any handling trial should be appropriate to the product’s mass and the risks involved.
The ISTA test procedure directory describes different distribution and testing contexts. It can support a discussion with a laboratory; it does not provide a universal divider height. Establish acceptance criteria for the product, decoration, accessories and function rather than judging only the external appearance of the box after testing.
Account for product and packing variation
Trial the combinations most likely to change upper clearance: the tallest product, a different closure and the box configuration with the least available space. The purpose is not to invent an arbitrary safety gap, but to understand which dimensional variations affect the agreed function. Keep the measuring method consistent so that apparently conflicting results can be investigated.
Also inspect any top component after the box has been opened. Its position may show whether the load path matched the design. If the component moved, investigate its location features and assembly sequence before deciding that greater divider height is the answer. Height is one design variable among several, and changing it can create new contacts elsewhere.
Record the decision on the drawing
- Finished partition height and its measuring reference.
- Product areas where contact is permitted or prohibited.
- Any intended load-bearing role.
- Components underneath and above the products.
- Loading method and gripping equipment.
- Checks required after closure and distribution testing.
Keep closure variants in the approved product list: the same bottle fitted with two pumps may need two assessments. To balance separation, access and upper support, share the complete configuration with Estic-Maillot. A side-view photograph and an assembled pack often explain more than overall product height alone.
Frequently asked questions
Should the divider extend above the product?
There is no general rule. An extension may help one arrangement and obstruct another. It must be consistent with the approved supports, closure and handling method.
Can an existing divider be shortened for a new product?
Shortening can change contacts, stability and force paths. Review the assembly and operating conditions before using the modification in production, even when the physical alteration appears minor.